Tooling system and method for assembling a vehicle driveline component

ABSTRACT

A method of assembling a vehicle driveline component that includes: positioning a rotary component and first race member on a fixture such that the first race member is concentric with a first race of the component; offsetting the first race member along the rotational axis relative to the first race; providing an annular bearing arrangement having balls and spacers; positioning the arrangement such that the centers of the balls are along a loading cylinder disposed concentrically about the rotational axis; moving the arrangement so the balls seat in the first race and the centers are distributed along an installation circle that is: a) larger in diameter than the loading cylinder if the first race is an outer race of a bearing assembly; or b) smaller in diameter than the loading cylinder if the first race is an inner race of a bearing assembly. A related tooling system is also provided.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional PatentApplication No. 63/048,382 filed Jul. 6, 2020, the disclosure of whichis incorporated by reference as if fully set forth in detail herein.

FIELD

The present disclosure relates to a tooling system and method forassembling a vehicle driveline component and more specifically forassembling bearings of the vehicle driveline component.

BACKGROUND

The statements in this section merely provide background informationrelated to the present disclosure and may not constitute prior art.

A driveline component can include rotational components (e.g., shafts,input pinions, ring gears) supported by bearings. For example, an axleassembly typically includes an input pinion supported by one or moreinput pinion bearings and a ring gear supported by one or more ring gearbearings. Such bearings typically include a plurality of bearingelements (e.g., tapered rollers) surrounded by an inner bearing race andan outer bearing race. The inner and outer bearing races are typicallyseparate components from the rotational component and the entire bearingassembly (i.e., the inner race, the outer race, and the bearingelements) is installed as a unit onto the rotational component or into ahousing into which the rotational component is then inserted. While suchconfigurations may be suitable for some applications, suchconfigurations can be difficult or costly to assemble and the number ofparts involved can make it difficult to conform to reduced spacerequirements of other applications.

In some other applications, the bearing elements are bearing balls andthe inner or outer bearing race is machined into the rotationalcomponent so that the inner or outer bearing race is integral to therotational component. However, such a configuration can be difficult andcostly to assemble and typically requires the bearing elements andopposite bearing race to be assembled onto the rotational component byhand and may require the bearing to be assembled while the rotationalcomponent is being positioned in the housing.

The present disclosure addresses these and other issues with assemblingtypical driveline components with bearings.

SUMMARY

This section provides a general summary of the disclosure and is not acomprehensive disclosure of its full scope or all of its features.

In one form, a method of assembling a vehicle driveline componentincludes providing a rotary component having a component body, aplurality of gear teeth and a first bearing race. The component body hasa rotational axis. The gear teeth and the first bearing race are fixedlycoupled to the component body. The method further includes providing afirst race member of a second bearing race, positioning the rotarycomponent and the first race member of the second bearing race on afirst assembly fixture such that the first race member of the secondbearing race is located on the first assembly fixture concentric withthe first bearing race. The method further includes offsetting the firstrace member of the second bearing race along the rotational axisrelative to the first bearing race and providing an annular bearingarrangement having a plurality of bearing balls and a plurality ofspacers, each of the spacers being disposed between an associated pairof the bearing balls. The method further includes positioning theannular bearing arrangement such that the centers of the bearing ballsare distributed along a loading cylinder that is disposed concentricallyabout the rotational axis. The method further includes moving theannular bearing arrangement so that the plurality of bearing balls seatin the first bearing race and the centers of the bearing balls aredistributed along an installation circle that is disposed concentricallyabout the rotational axis, the installation circle being: a) larger indiameter than the loading cylinder if the first bearing race is an outerbearing race of a bearing assembly; or b) smaller in diameter than theloading cylinder if the first bearing race is an inner bearing race of abearing assembly. According to a variety of alternate forms: the methodfurther includes arranging the plurality of bearing balls and theplurality of spacers into the annular bearing arrangement on a secondassembly fixture so that the centers of bearing balls are distributedalong a staging cylinder having a diameter that is equal to the diameterof the loading cylinder, and removing the annular bearing arrangementfrom the second assembly fixture before positioning the annular bearingarrangement concentrically about the rotational axis; the loadingcylinder is smaller in diameter than the installation circle, whereinwhen the centers of the bearing balls of the annular bearing arrangementare distributed along the loading cylinder the plurality of bearingballs includes a set of first balls and a set of second balls, whereinthe first balls are axially offset from the second balls, and whereineach first ball is disposed circumferentially between a correspondingpair of the second balls; the first bearing race is unitarily andintegrally formed with the component body; the plurality of gear teethare unitarily and integrally formed with the component body; providingthe annular bearing arrangement includes arranging the bearing balls andthe spacers into the annular bearing arrangement on a second assemblyfixture; positioning the annular bearing arrangement includes operatinga robotic arm to move the annular bearing arrangement from the secondassembly fixture to the first assembly fixture; offsetting the firstrace member of the second bearing race along the rotational axisincludes lowering the first race member of the second bearing race, andwherein moving the annular bearing arrangement so that the plurality ofbearing balls seat in the first bearing race includes releasing theannular bearing arrangement from a holder such that the bearing ballsand spacers of the annular bearing arrangement drop into the firstbearing race; the method further includes forming a subassembly thatcomprises the rotary component, the annular bearing arrangement, and thefirst and second races, wherein the subassembly is configured such thatthe bearing balls of the annular bearing arrangement are disposedbetween and abut the first bearing race and the first race member of thesecond bearing race; the method further includes installing thesubassembly as a unit to a housing, wherein the first race member of thesecond bearing race is mounted directly to the housing.

In another form, a tooling system for assembling a subassembly to ahousing includes a first assembly fixture, and an assembly machine. Thesubassembly includes a component body, a plurality of gear teeth, afirst bearing race, a first race member of a second bearing race, and abearing arrangement. The component body is rotatable about a rotaryaxis, the plurality of gear teeth and the first bearing race is fixedlycoupled to the component body. The first race member of the secondbearing race is disposed concentrically about the rotational axis. Thebearing arrangement includes a plurality of bearing balls and aplurality of spacers. Each of the spacers is disposed between anadjacent pair of the bearing balls. The first assembly fixture includesa first support structure and a second support structure. The firstsupport structure is configured to support the rotary component. Thesecond support structure is configured to support the first race memberof the second bearing race concentrically about the rotational axis ofthe rotary component. The second support structure is movable relativeto the first support structure between a first support position and asecond support position. Movement of the second support structurebetween the first and second support positions translates the first racemember of the second bearing race relative to the first bearing racealong the rotational axis. The assembly machine includes a firstalignment member and a second alignment member. The first alignmentmember defines a loading axis and a first cylindrical alignment surfacedisposed concentrically about the loading axis. The second alignmentmember is disposed concentrically about the loading axis and has a raceabutment surface that is configured to abut an axial end of the firstrace member. The second alignment member is movable relative to thefirst alignment member along the loading axis between a first positionand a second position. The first cylindrical alignment surface and thesecond alignment member cooperate to define an annular chamberconfigured to receive the bearing arrangement such that the plurality ofbearing balls and the plurality of spacers are disposed in an annularbearing arrangement that is centered about the loading axis. When thesecond alignment member is in the second position an end of the firstcylindrical alignment surface and an end of the second alignment memberare spaced apart a greater distance than when the second alignmentmember is in the first position such that when in the first position theannular bearing arrangement is retained in the annular chamber and whenin the second position the annular bearing arrangement is free to exitthe annular chamber through an annular gap between the end of the firstcylindrical alignment surface and the end of the second alignmentmember. According to a variety of alternate forms: a diameter of thefirst cylindrical alignment surface is either: a) equal to or largerthan a diameter of an end of the first bearing race if the first bearingrace is an inner bearing race of a bearing assembly, or b) equal to orsmaller than a diameter of an end of the first bearing race if the firstbearing race is an outer bearing race of a bearing assembly; the secondalignment member is disposed about the first cylindrical alignmentsurface and the second alignment member includes a ramp that tapersradially inward toward the end of the second alignment member; theassembly machine further includes a push sleeve disposed concentricallybetween the first cylindrical alignment surface and the second alignmentmember, the push sleeve being movable along the loading axis relative tothe first alignment member and the second alignment member between aretracted position and an extended position, wherein in the extendedposition the push sleeve is disposed further into the annular chamberthan when in the retracted position; the assembly machine furtherincludes a first biasing member and a second biasing member, the firstbiasing member biasing the first alignment member in a first axialdirection relative to the push sleeve, the second biasing member biasingthe second alignment member in the first axial direction relative to thepush sleeve; the first cylindrical alignment surface is disposed aboutthe second alignment member and the second alignment member includes aramp that tapers radially outward toward the end of the second alignmentmember; the assembly machine further includes a push sleeve disposedconcentrically between the first cylindrical alignment surface and thesecond alignment member, the push sleeve being movable along the loadingaxis relative to the first alignment member and the second alignmentmember between a retracted position and an extended position, wherein inthe extended position the push sleeve is disposed further into theannular chamber than when in the retracted position; the assemblymachine further includes a first biasing member and a second biasingmember, the first biasing member biasing the first alignment member in afirst axial direction relative to the push sleeve, the second biasingmember biasing the second alignment member in the first axial directionrelative to the push sleeve; the assembly machine includes a clampmember movable between a first clamp position and a second clampposition, wherein when the clamp member is in the first clamp positionthe clamp member engages the second alignment member to couple thesecond alignment member to the first alignment member, and when theclamp member is in the second clamp position the clamp member isdisengaged from the second alignment member and the second alignmentmember is decoupled from the first alignment member; the assemblymachine includes tool configured to pick up and move the rotarycomponent with the annular bearing arrangement disposed between thefirst bearing race and the first race member of the second bearing race.

Further areas of applicability will become apparent from the descriptionprovided herein. It should be understood that the description andspecific examples are intended for purposes of illustration only and arenot intended to limit the scope of the present disclosure.

DRAWINGS

In order that the disclosure may be well understood, there will now bedescribed various forms thereof, given by way of example, referencebeing made to the accompanying drawings, in which:

FIG. 1 is a schematic plan view of an example vehicle including adriveline component assembled according to the teachings of the presentdisclosure;

FIG. 2 is a cross-sectional view of the driveline component of FIG. 1;

FIG. 3 is a tooling system for assembling a driveline componentaccording to the teachings of the present disclosure;

FIG. 4 is a perspective view of tool assembly of the tooling system ofFIG. 3;

FIG. 5 is a perspective view of a first tool of the tool assembly ofFIG. 4;

FIG. 6 is an exploded perspective view of the first tool of FIG. 5,illustrated with an arrangement of bearing elements in accordance withthe teachings of the present disclosure;

FIG. 7 is a cross-sectional view of the first tool of FIGS. 5 and 6,illustrated in a first position of a bearing assembly procedureaccording to the teachings of the present disclosure;

FIG. 8 is a cross-sectional view of the first tool similar to FIG. 7,illustrated in a second position of the bearing assembly procedureaccording to the teachings of the present disclosure;

FIG. 9 is a cross-sectional view of the first tool similar to FIG. 8,illustrated in a third position of the bearing assembly procedureaccording to the teachings of the present disclosure;

FIG. 10 is a perspective view of a second tool of the tool assembly ofFIG. 4;

FIG. 11 is an exploded perspective view of the second tool of FIG. 5,illustrated with an arrangement of bearing elements in accordance withthe teachings of the present disclosure;

FIG. 12 is a cross-sectional view of the second tool of FIGS. 10 and 11,illustrated in a first position of a bearing assembly procedureaccording to the teachings of the present disclosure;

FIG. 13 is a cross-sectional view of the second tool similar to FIG. 12,illustrated in a second position of the bearing assembly procedureaccording to the teachings of the present disclosure; and

FIG. 14 is a cross-sectional view of the second tool similar to FIG. 13,illustrated in a third position of the bearing assembly procedureaccording to the teachings of the present disclosure.

The drawings described herein are for illustration purposes only and arenot intended to limit the scope of the present disclosure in any way.

DETAILED DESCRIPTION

The following description is merely exemplary in nature and is notintended to limit the present disclosure, application, or uses. Itshould be understood that throughout the drawings, correspondingreference numerals indicate like or corresponding parts and features.

Referring to FIG. 1, a vehicle having an exemplary vehicle drivelinecomponent constructed in accordance with the teachings of the presentdisclosure is generally indicated by reference numeral 10. In theparticular example provided, the vehicle driveline component is an axleassembly (and more specifically, a rear axle assembly), but it will beappreciated that the teachings of the present disclosure haveapplication to various other types of vehicle driveline components, suchas power take-off units, and drive units that are fully, partly oralternately powered with an electric motor, for example.

The vehicle 10 can have a power train 12 and a drive line or drive train14. The power train 12 can be conventionally constructed and cancomprise a power source 16 and a transmission 18. The power source 16can be configured to provide propulsive power and can comprise aninternal combustion engine and/or an electric motor, for example. Thetransmission 18 can receive propulsive power from the power source 16and can output power to the drive train 14. The transmission 18 can havea plurality of automatically or manually selected gear ratios. The drivetrain 14 in the particular example provided is of a two-wheel,rear-wheel drive configuration, but those of skill in the art willappreciate that the teachings of the present disclosure are applicableto other drive train configurations, including four-wheel driveconfigurations, all-wheel drive configurations, and front-wheel driveconfigurations. The drive train 14 can include a propshaft 20 and anaxle assembly 22 (e.g., the rear axle assembly). The propshaft 20 cancouple the transmission 18 to the axle assembly 22 such that rotarypower output of the transmission 18 is received by the axle assembly 22.The axle assembly 22 can distribute the rotary power to a set of drivewheels (e.g., rear vehicle wheels 26).

Referring to FIG. 2, the axle assembly 22 can include a housing assembly30, an input pinion 32, a ring gear 34, a differential assembly 36, anda pair of axle shafts 38. In the example provided, the axle assembly 22is constructed as described in U.S. Pat. No. 10,487,933, the entirety ofwhich is incorporated herein by reference, though other configurationsmay be used. In general, the input pinion 32 is a rotary component thatcan be rotatable about a first axis 40, while the ring gear 34 isanother rotary component and, along with the differential assembly 36,can be rotatable about a second axis 42 that can be transverse orperpendicular to the first axis 40.

The housing assembly 30 defines a differential cavity 50 into which thedifferential assembly 36 is received. The input pinion 32 is received inthe differential cavity 50 and includes a shaft 52 (i.e., a componentbody) and a plurality of pinion teeth 54 (i.e., gear teeth) proximate toone axial end 56 of the shaft 52. The input pinion 32 can define aninternal cavity 58 that opens through an opposite axial end 60 of theshaft 52. The input pinion 32 can be drivingly coupled to the propshaft20 (FIG. 1) to receive input torque therefrom.

A pinion bearing 62 supports the input pinion 32 for rotation relativeto the housing assembly 30 about the first axis 40. The pinion bearing62 can have an inner bearing race 64, an outer bearing race 66, and aplurality of pinion bearing elements 68 that are disposedcircumferentially about the first axis 40. In the example provided, thepinion bearing elements 68 are spherical bearing balls 68 a (labeled inFIG. 6) and generally cylindrical spacers 68 b (shown in FIG. 6) havingconcave surfaces (not specifically shown) that engage adjacent bearingballs 68 a (labeled in FIG. 6), though other configurations could beused. In the example provided, the inner bearing race 64 is unitarilyand integrally formed (e.g., machined) into the shaft 52 of the inputpinion 32. The outer bearing race 66 is disposed about the inner bearingrace 64. In the example provided, the outer bearing race 66 can have afirst outer race member 70 and a second outer race member 72. The pinionbearing elements 68 are disposed between the inner bearing race 64 andthe outer bearing race 66 and the bearing balls 68 a can be in contactwith the inner and outer bearing races 64, 66.

The ring gear 34 is received in the differential cavity 50 and includesa plurality of ring gear teeth 74 that are meshingly engaged to thepinion teeth 54. The ring gear 34 can be a bevel gear (e.g., a spiralbevel gear, such as a hypoid gear).

A ring gear bearing 78 supports the ring gear 34 for rotation relativeto the housing assembly 30 about the second axis 42. The ring gearbearing 78 has an outer bearing race 80, an inner bearing race 82, and aplurality of ring gear bearing elements 84. In the example provided, thering gear bearing elements 84 are spherical bearing balls 84 a (labeledin FIG. 11) and generally cylindrical spacers 84 b (shown in FIG. 11)having concave surfaces (not specifically shown) that engage adjacentbearing balls 84 a (labeled in FIG. 11), though other configurationscould be used. The inner bearing race 82 is radially inward of the outerbearing race 80 and the bearing balls 84 a can contact the outer andinner bearing races 80, 82. In the example provided, the outer bearingrace 80 is unitarily and integrally formed (e.g., machined) into thering gear 34. Alternatively, the outer bearing race 80 can be configuredas described in U.S. Pat. No. 10,487,933, with a first race memberintegrally formed with the ring gear 34 and a separate second racemember coupled to the ring gear 34. Returning to the example provided inFIG. 2, the inner bearing race 82 can include a first inner race member86 and a second inner race member 88.

The differential assembly 36 can be drivingly coupled to the axle shafts38 which can be drivingly coupled to drive wheels of a vehicle (e.g.,the rear wheels 26 shown in FIG. 1) and the differential assembly 36 canbe configured to permit speed differentiation between the two axleshafts 38. In the example provided, the ring gear 34 is fixedly coupledto an input 92 (e.g., the differential case) of the differentialassembly to provide input torque thereto.

Referring to FIG. 3, a tooling system 110 for assembling a drivelinecomponent such as the axle assembly 22 (FIG. 2) is illustrated. Whiledescribed with reference to the rear axle assembly 22, those of skill inthe art will appreciate that the teachings of the present disclosure areapplicable to other arrangements, such as front axle assemblies, centraldifferentials, power take-off units, or transfer cases, for example. Thetooling system 110 can include an assembly machine 114 and a pluralityof assembly fixtures 118. In the example provided, the plurality ofassembly fixtures 118 includes a pinion fixture 122, a pinion bearingfixture 126, a ring gear fixture 130, and a ring gear bearing fixture134.

The assembly machine 114 includes a positioning device 138, a toolassembly 142 (shown in FIG. 4) coupled to the positioning device 138,and a controller 146 in communication with the positioning device 138and the tool assembly 142 (FIG. 4). The controller 146 is configured tooperate the positioning device 138 to move the tool assembly 142 (FIG.4) and to operate the tool assembly 142 (FIG. 4) to manipulatecomponents as described below. In the example provided, the positioningdevice 138 is an autonomous multi-axis robotic arm and the tool assembly142 (FIG. 4) is an end effector assembly, though other configurationscan be used such as a robotic gantry or lift assist device for example.The assembly machine 114 may include a mount 150 configured to removablycouple the positioning device 138 to the tool assembly 142 (FIG. 4). Themount 150 can be configured to supply pneumatic power, vacuum suction,electrical power, and/or electrical signals to the tool assembly 142(FIG. 4).

Referring to FIG. 4, an example of the tool assembly 142 is illustrated.The tool assembly 142 can include a mating mount 210 configured to beremovably coupled to the mount 150 (FIG. 3) to be moved by thepositioning device 138 (FIG. 3) and to receive compressed air, vacuumsuction, electrical power and/or electrical signals therefrom. In theexample provided, the tool assembly 142 also includes a base 214, afirst tool 218 (e.g., a first end effector), a second tool 222 (e.g., asecond end effector), a third tool 226 (e.g., a third end effector), anda fourth tool 228 (e.g., a fourth end effector). The tools 218, 222,226, 228 and the mating mount 210 are each coupled to different sides ofthe base 214.

Those of skill in the art will appreciate that the teachings of thepresent disclosure are applicable to configurations with differentnumbers of tools coupled to the base 214 of the tool assembly 142, suchas only one of the tools 218, 222, 226, 228, any two of the tools 218,222, 226, 228, or any three of the tools 218, 222, 226, 228 beingsupported by the base. In one alternative, not specifically shown, eachtool 218, 222, 226, 228 has its own mating mount 210 and the positioningdevice 138 is configured to swap between tools 218, 222, 226, 228. Inanother alternative configuration, not specifically shown, the toolingsystem 110 can include more than one positioning device with each movingone or more of the tools 218, 222, 226, 228.

Referring to FIGS. 5 and 6, the first tool 218 includes a push sleeve310, an inner sleeve 312 (also referred to herein as the first alignmentmember), an outer sleeve 314, a second alignment member 316, and aclamping device 318. The push sleeve 310 is fixedly coupled to the base214 (FIG. 4). The push sleeve 310 is disposed about a first loading axis320 and has a push surface 322 at the axial end opposite the base 214(FIG. 4). The push sleeve 310 can define a central bore 324 that iscentered on the first loading axis 320. In the example provided, thepush sleeve 310 defines a pair of slots 326 (one of which is shown inFIG. 6) through diametrically opposite sides of the push sleeve 310. Theslots 326 are open into the central bore 324 and extend longitudinallyparallel to the first loading axis 320.

The inner sleeve 312 is annularly disposed about the first loading axis320 and is received within the central bore 324 of the push sleeve 310.The inner sleeve 312 is axially translatable relative to the push sleeve310. In the example provided, a pair of lugs 328 are coupled todiametrically opposite sides of the inner sleeve 312 and extend radiallyoutward therefrom. Each lug 328 is received in a corresponding one ofthe slots 326 of the push sleeve 310 to permit relative axial movementand inhibit relative rotation between the push sleeve 310 and the innersleeve 312. One or more biasing members (e.g., springs 330) can bepositioned to bias the inner sleeve 312 in an axial direction 332. Inthe example shown, two springs 330 are included with each engaging acorresponding one the lugs 328 and the push sleeve 310. In analternative configuration, not specifically shown, one or more springs330 can directly engage the inner sleeve 312 and the push sleeve 310. Inthe example provided, the inner sleeve 312 defines a central bore 334that is configured to receive vacuum suction from the base 214 (FIG. 4).

The outer sleeve 314 is disposed concentrically about the push sleeve310 and is axially translatable relative to the push sleeve 310. In theexample provided, the outer sleeve 314 defines a pair of slots 336through diametrically opposite sides of the outer sleeve 314. A pair oflugs 338 are coupled to diametrically opposite sides of the push sleeve310 and extend radially outward therefrom. Each lug 338 is received in acorresponding one of the slots 336 of the outer sleeve 314 to permitrelative axial movement and inhibit relative rotation between the pushsleeve 310 and the outer sleeve 314. One or more biasing members (e.g.,springs 340) can be positioned to bias the outer sleeve 314 in the axialdirection 332. In the example provided, two springs 340 engagecorresponding ones of the lugs 338 and the outer sleeve 314. In analternative configuration, not specifically shown, one or more springscan directly engage the outer sleeve 314 and the push sleeve 310.

The second alignment member 316 is an annular body that includes anannular ramp surface 342, a lip 344, and a lower terminal end 346. Theannular ramp surface 342 may optionally include a plurality of recesses343 that have a spherical concave shape so that each recess 343 receivesand locates a corresponding one of the bearing balls 68 a.

The clamping device 318 is configured to releasably couple the secondalignment member 316 to the outer sleeve 314 when concentricallydisposed therewith. In the example provided, the clamping device 318includes a pair of actuators 348 mounted to the exterior of the outersleeve 314. Each actuator 348 is configured to move a correspondingclamp member 352 between a clamped position wherein the clamp members352 grip the lip 344 of the second alignment member 316 and a releasedposition wherein the second alignment member 316 is free to drop axiallyrelative to the outer sleeve 314. In the example provided, the actuators348 can move the clamp member 352 axially and rotate the clamp members352 in order to engage and disengage the lip 344, though other motionscan be used. In the example provided, each actuator 348 includes sleeve349 that defines a groove 351 or track along which a follower pin (notspecifically shown) on a shaft 353 of the clamp member 352 can ride. Thetrack 351 extends axially and circumferentially along the sleeve 349 tocause the clamp member 352 to rotate. In the example provided, theactuators 348 are pneumatically powered, though other configurations canbe used such as electrically powered actuators for example.

Referring to FIGS. 10 and 11, the second tool 222 includes a push sleeve410, an outer sleeve 412 (also referred to herein as the first alignmentmember), an inner sleeve 414, a second alignment member 416, and aclamping device 418. The push sleeve 410 is fixedly coupled to the base214 (FIG. 4). The push sleeve 410 is disposed about a second loadingaxis 420 and has a push surface 422 at the axial end opposite the base214 (FIG. 4). The push sleeve 410 can define a central bore 424 coaxialwith the second loading axis 420. In the example provided, the pushsleeve 410 defines a pair of slots 426 through diametrically oppositesides of the push sleeve 410. The slots 426 are open into the centralbore 424 and extend longitudinally parallel to the second loading axis420.

The inner sleeve 414 is annularly disposed about the second loading axis420 and is received concentrically within the central bore 424 of thepush sleeve 410. The inner sleeve 414 is axially translatable relativeto the push sleeve 410. In the example provided, a pair of lugs 428 arecoupled to diametrically opposite sides of the inner sleeve 414 andextend radially outward therefrom. Each lug 428 is received in acorresponding one of the slots 426 of the push sleeve 410 to permitrelative axial movement and inhibit relative rotation between the pushsleeve 410 and the inner sleeve 414. One or more biasing members (e.g.,springs 430) can be positioned to bias the inner sleeve 414 in an axialdirection 432. In the example provided, two springs 430 are includedwith each engaging a corresponding one the lugs 428 and the push sleeve410. In an alternative configuration, not specifically shown, one ormore springs 430 can directly engage the inner sleeve 414 and the pushsleeve 410. In the example provided, the inner sleeve 414 defines acentral bore 434 and the clamping device is disposed within the centralbore 434.

The second alignment member 416 includes a cylindrical body 436 and anannular ramp surface 438 (shown in FIG. 12). The clamping device 418 isconfigured to releasably couple the second alignment member 416concentrically to the inner sleeve 414. In the example provided, theclamping device 418 includes an actuator 442 received through thecentral bore 434 and mounted to the inner sleeve 414. The actuator 442is configured to move a clamp member 444 between a clamped position(shown in FIG. 12) wherein the clamp member 444 extends through anaperture 446 in the cylindrical body 436 of the second alignment member416 to grip a lip or surface 448 of the cylindrical body 436 and areleased position (shown in FIG. 10) wherein the second alignment member416 is free to drop axially relative to the inner sleeve 414. In theexample provided, the actuator 442 can move the clamp member 444 axiallyand rotate the clamp member 444 in order to engage and disengage thesurface 448, though other motions can be used. In the example provided,the actuator 442 and clamp member 444 can be constructed similarly tothe actuator 348 and clamp member 352 described above. In the exampleprovided, the actuator 442 is pneumatically powered, though otherconfigurations can be used such as electrically powered actuators forexample.

The outer sleeve 412 is disposed concentrically about the push sleeve410 and is axially translatable relative to the push sleeve 410. In theexample provided, the outer sleeve defines a pair of slots 450 throughdiametrically opposite sides of the outer sleeve 412. A pair of lugs 452are coupled to diametrically opposite sides of the push sleeve 410 andextend radially outward therefrom. Each lug 452 is received in acorresponding one of the slots 450 of the outer sleeve 412 to permitrelative axial movement and inhibit relative rotation between the pushsleeve 410 and the outer sleeve 412. One or more biasing members (e.g.,springs 454) can be positioned to bias the outer sleeve 412 in the axialdirection 432. In the example shown, two springs 454 are included witheach engaging a corresponding one of the lugs 452 and the outer sleeve412. In an alternative configuration, not specifically shown, one ormore springs 454 can directly engage the outer sleeve 412 and the pushsleeve 410.

Returning to FIG. 3, the pinion fixture 122 includes a pinion supportstructure 710 (also referred to herein as the first support structure)disposed about a pinion support axis 712 and a race support structure714 (also referred to herein as a second support structure) disposedconcentrically about the pinion support structure 710. As shown in FIGS.7-9, the pinion support structure 710 has a pinion support surface 716that can engage the input pinion 32 in order to support the input pinion32 such that the rotational axis of the input pinion 32 is coaxial withthe pinion support axis 712. In the example provided, the pinion supportsurface 716 defines a generally conically shaped cavity such that thepinion teeth 54 of the input pinion 32 are supported by the pinionsupport surface 716, though other configurations can be used.

The race support structure 714 includes an annular race support surface718 configured to support the first outer race member 70 coaxial withthe pinion support axis 712. The race support structure 714 is axiallymovable relative to the pinion support structure 710. In the exampleprovided, an actuator 720 (FIG. 3) is connected to the race supportstructure 714 and configured to move the race support structure 714along the pinion support axis 712 between the position shown in FIG. 7and the position shown in FIG. 8.

The actuator 720 can be any suitable type of linear actuator, such as apneumatic piston actuator or a solenoid actuator for example. In analternative configuration, not specifically shown, the actuator 720 canbe configured to move the pinion support structure 710 while the racesupport structure 714 remains stationary. In an alternativeconfiguration, not specifically shown, a return spring can bias the racesupport structure 714 axially toward the position shown in FIG. 7 andthe actuator 720 may optionally be omitted such that the first tool 218can contact and push the race support structure 714 to overcome thereturn spring and move the race support structure 714 to the positionshown in FIG. 8.

Returning to FIG. 3, the pinion bearing fixture 126 includes an innercylinder 810 and the second alignment member 316. The second alignmentmember 316 can be disposed concentrically about the inner cylinder 810to define an annular space within which the pinion bearing elements 68can be arranged, alternating between bearing balls 68 a (labeled in FIG.6) and spacers 68 b (labeled in FIG. 6). When arranged between the innercylinder 810 and the second alignment member 316, the center of eachbearing ball 68 a (labeled in FIG. 6) and the center of each spacer 68 b(labeled in FIG. 6) is distributed along a staging circle or stagingcylinder (not specifically shown) having a larger diameter than a circle(not specifically shown) along which the centers of the pinion bearingelements 68 are distributed when installed as shown in FIG. 2

Referring to FIG. 4, the third tool 226 includes a first gripper 510 anda first retention device 512. The first gripper 510 includes a pluralityof fingers 514 spaced about a third loading axis 516 of the third tool226. The fingers 514 are movable relative to the base 214 and configuredto grip and release parts such as the first outer race member 70 (FIG.2) and the second outer race member 72 (FIG. 2). In the exampleprovided, the fingers 514 are moved by one or more pneumatic actuators(not shown), though other configurations can be used such as electronicactuators for example.

The first retention device 512 is configured to engage and support theinput pinion 32 (FIG. 2) for motion with the third tool 226. In theexample provided, the first retention device 512 includes a vacuum cap518 disposed radially inward of the fingers 514, though otherconfigurations can be used, such as additional fingers (not shown) ormagnets (not shown) for example. The vacuum cap 518 defines a suctionaperture 522. The suction aperture 522 is in fluid communication with avacuum source (not shown) via the base 214. The vacuum cap 518 may beaxially fixed relative to the base 214 or may be axially movablerelative to the base 214. The vacuum cap 518 is configured to form aseal with the axial end 60 (FIG. 2) of the shaft 52 of the input pinion32 (FIG. 2) while the suction aperture 522 can provide suction to theinternal cavity 58 (FIG. 2) to secure the input pinion 32 (FIG. 2) tothe third tool 226. In one optional configuration, a spring (not shown)may bias the vacuum cap 518 axially relative to the base 214 such thatthe vacuum cap 518 is biased into sealing contact with the input pinion32 (FIG. 2).

The fourth tool 228 includes a second gripper 610 and a second retentiondevice 612. The second gripper 610 includes a plurality of fingers 614spaced about a fourth loading axis 616 of the fourth tool 228. Thefingers 614 are movable relative to the base 214 and configured to gripand release parts such as the first inner race member 86 (FIG. 2) andthe second race member 88 (FIG. 2). In the example provided, the fingers614 are moved by one or more pneumatic actuators (not shown), thoughother configurations can be used such as electronic actuators forexample. The second retention device 612 is configured to engage andsupport the ring gear 34 (FIG. 2) for motion with the fourth tool 228.In the example provided, the second retention device 612 includes aplurality of magnets 618 with each mounted on a corresponding pneumaticcylinder 620 spaced about the fourth loading axis 616, though otherconfigurations can be used, such as additional fingers (not shown),electromagnets (not shown), or suction devices (not shown) for example.

Referring to FIG. 3, the ring gear fixture 130 includes a ring gearsupport structure 910 (also referred to herein as the first supportstructure) disposed about a ring gear support axis 912 and a racesupport structure 914 (also referred to herein as the second supportstructure). The ring gear support structure 910 is disposedconcentrically about the race support structure 914. As shown in FIGS.12-14, the ring gear support structure 910 has a ring gear supportsurface 916 that can engage the ring gear 34 in order to support it suchthat the rotational axis of the ring gear 34 is coaxial with the ringgear support axis 912. In the example provided, the ring gear supportsurface 916 defines a generally conically shaped cavity such that theteeth 74 of the ring gear 34 are supported by the ring gear supportsurface 916, though other configurations can be used.

The race support structure 914 includes a race support surface 918configured to support the first inner race member 86 centered on thering gear support axis 912. The race support structure 914 is axiallymovable relative to the ring gear support structure 910. In the exampleprovided, an actuator 920 (FIG. 3) is connected to the race supportstructure 914 and configured to move the race support structure 914along the ring gear support axis 912 between the position shown in FIG.12 and the position shown in FIG. 13. The actuator 920 can be anysuitable type of linear actuator, such as a pneumatic piston actuator ora solenoid actuator for example. In an alternative configuration, notspecifically shown, the actuator 920 can be configured to move the ringgear support structure 910 while the race support structure 914 remainsstationary. In an alternative configuration, not specifically shown, areturn spring can bias the race support structure 914 axially toward theposition shown in FIG. 13 and the actuator 920 may optionally be omittedsuch that the second tool 222 can contact and push the race supportstructure 914 to overcome the return spring and move the race supportstructure 914 to the position shown in FIG. 13.

Returning to FIG. 3, the ring gear bearing fixture 134 includes an outercylinder 1010 and the second alignment member 416. The outer cylinder1010 can be disposed concentrically about the second alignment member416 to define an annular space within which the ring gear bearingelements 84 can be arranged, alternating between bearing balls 84 a(labeled in FIG. 11) and spacers 84 b (labeled in FIG. 11). Whenarranged between the outer cylinder 1010 and the second alignment member416, the center of each bearing ball 84 a (labeled in FIG. 11) and thecenter of each spacer 84 b (labeled in FIG. 11) is distributed along astaging cylinder (not specifically shown) having a smaller diameter thana circle (not specifically shown) along which the centers of the ringgear bearing elements 84 are distributed when installed as shown in FIG.2. When arranged between the outer cylinder 1010 and the secondalignment member 416, adjacent bearing balls 84 a (labeled in FIG. 11)are axially offset from one another along the cylinder (not specificallyshown) along which the centers of the bearing balls 84 a (labeled inFIG. 11) are distributed. In other words, the bearing balls 84 a(labeled in FIG. 11) include a set of first balls 84 a 1 (labeled inFIG. 11) that are axially offset from a set of second balls 84 a 2(labeled in FIG. 11), with each first ball 84 a 1 (labeled in FIG. 11)being disposed circumferentially between a corresponding pair of thesecond balls 84 a 2 (labeled in FIG. 11).

Referring to FIG. 3, in operation, the controller 146 can operate thepositioning device 138, the tool assembly 142, and the fixtures 122, 130to assemble the pinion bearing 62 (FIG. 2) about the input pinion 32 andassemble the ring gear bearing 78 (FIG. 2) within the ring gear 34 asdescribed in greater detail below. The controller 146 can alsooptionally operate the positioning device 138 and the tool assembly 142to position the input pinion 32 with the assembled pinion bearing 62(FIG. 2) and the ring gear 34 with the assembled ring gear bearing 78(FIG. 2) into the housing assembly 30 in the position shown in FIG. 2.

In the example provided, a pinion staging fixture 1110 supports theinput pinion 32 concentrically with the outer race 66 and a ring gearstaging fixture 1112 supports the ring gear 34 concentrically with theinner bearing race 82. A housing staging fixture 1114 can optionallysupport the housing assembly 30.

With reference to FIGS. 3 and 4, the process of the tool assembly 142assembling the input pinion 32 with the pinion bearing 62 (FIG. 2) isdescribed. The input pinion 32 and the outer bearing race 66 arepositioned on the pinion staging fixture 1110 and the positioning device138 moves the third tool 226 to be concentric with the input pinion 32.The first gripper 510 can then grip the outer bearing race 66 while theinput pinion 32 is secured to the tool assembly 142 by the firstretention device 512. The positioning device 138 can then move the thirdtool 226 until the rotational axis of the input pinion 32 is alignedwith the pinion support axis 712 of the pinion fixture 122. The firstretention device 512 can then release the input pinion 32 so that it issupported by the pinion support surface 716 (FIG. 7) and the firstgripper 510 can release the outer bearing race 66 so that the firstouter race member 70 is supported by the race support surface 718 (FIG.7) concentrically with the input pinion 32. The first gripper 510 canthen grip the second outer race member 72 and remove it from the pinionfixture 122.

The pinion bearing elements 68 are arranged in the pinion bearingfixture 126 as discussed above. The first tool 218 (without the secondalignment member 316, which is located in the pinion bearing fixture 126at this point) is moved to be coaxial with the pinion bearing fixture126. The clamping device 318 is activated to clamp the second alignmentmember 316 to the outer sleeve 314.

Referring to FIGS. 7-9, with the second alignment member 316 clamped tothe outer sleeve 314, an inward facing cylindrical surface 1210 of thesecond alignment member 316 is spaced apart from an outward facingcylindrical surface 1214 (i.e., cylindrical alignment surface) of theinner sleeve 312 to define an annular loading chamber 1218. The distancebetween the inward facing cylindrical surface 1210 and the outwardfacing cylindrical surface 1214 is slightly larger than the diameter ofeach bearing ball 68 a such that the arrangement of pinion bearingelements 68 is received in the annular loading chamber 1218 when thesecond alignment member 316 is clamped to the outer sleeve 314. Theannular ramp surface 342 is angled to extend radially inward from theinward facing cylindrical surface 1210 to the lower terminal end 346 todefine a gap 1222 with the outward facing cylindrical surface 1214. Thegap 1222 is smaller than the diameter of each bearing ball 68 a and eachspacer 68 b (shown in FIG. 6) such that the pinion bearing elements 68are inhibited from falling out of the annular loading chamber 1218. Thepositioning device 138 (FIG. 3) can then move the first tool 218 to beabove and coaxial to the input pinion 32 as shown in FIG. 7.

The actuator 720 (FIG. 3) can be operated to move the race supportstructure 714 axially downward relative to the pinion support structure710, so that the first outer race member 70 is axially offset from theinner bearing race 64 in the manner shown in FIG. 8. The first tool 218can then move axially downward until the inner sleeve 312 contacts ashoulder 1226 of the inner bearing race 64. The outward facingcylindrical surface 1214 has a diameter that is approximately equal toor slightly larger than the shoulder 1226 of the inner bearing race 64.Thus, the centers of the bearing balls 68 a are distributed along aloading cylinder or loading circle 814 (shown in FIG. 6) that has adiameter that is greater than a diameter of a circle (not specificallyshown) along which the centers of the bearing balls 68 a are distributedwhen seated in the inner bearing race 64 as shown in FIG. 9. In theexample provided, the loading cylinder or loading circle 814 has adiameter equal to that of the corresponding staging cylinder (notspecifically shown).

The push sleeve 310 and the outer sleeve 314 can continue to moveaxially downward while the inner sleeve 312 remains stationary againstthe shoulder 1226 until in the position shown in FIG. 8. In thisposition, an axial end surface 1238 (i.e., race abutment surface) of thesecond alignment member 316 abuts the first outer race member 70 and thegap 1222 has increased to be larger than the diameter of the bearingballs 68 a and the spacers 68 b (FIG. 6). As such, the pinion bearingelements 68 are released and can fall under gravity into the innerbearing race 64, guided by the ramp surface 342. In the exampleprovided, the push sleeve 310 may also continue to move downwardrelative to the inner sleeve 312 and the outer sleeve 314 (e.g., to anextended position) to push the pinion bearing elements 68 into the innerbearing race 64.

After the pinion bearing elements 68 are seated in the inner bearingrace 64, the actuator 720 (FIG. 3) can be operated again while the firsttool 218 retracts in order to move the first outer race member 70upwards to engage the pinion bearing elements 68 as shown in FIG. 9. Thefirst gripper 510 (FIG. 4) may then place the second outer race member72 (FIG. 3) on top of the first outer race member 70 and the third tool226 (FIG. 4) may optionally move the input pinion 32 with the assembledpinion bearing 62 (FIG. 2) together as a subassembly, such as into thehousing assembly 30 (FIG. 3).

Returning to FIGS. 3 and 4, the process of the tool assembly 142assembling the ring gear 34 with the ring gear bearing 78 (FIG. 2) isdescribed. The ring gear 34 and the inner bearing race 82 are positionedon the ring gear staging fixture 1112 and the positioning device 138moves the fourth tool 228 to be coaxial with the ring gear 34. Thesecond gripper 610 can then grip the inner bearing race 82 while thering gear 34 is secured to the tool assembly 142 by the second retentiondevice 612. The positioning device 138 can then move the fourth tool 228until the rotational axis of the ring gear 34 is aligned with the ringgear support axis 912 of the ring gear fixture 130. The second retentiondevice 612 can then release the ring gear 34 so that the ring gear 34 issupported by the ring gear support surface 916 (FIG. 12) and the secondgripper 610 can release the inner bearing race 82 so that the firstinner race member 86 is supported by the race support surface 918 (FIG.12) concentrically with the ring gear 34. The second gripper 610 canthen grip the second race member 88 (FIG. 2) and remove it from the ringgear fixture 130.

The ring gear bearing elements 84 are arranged in the ring gear bearingfixture 134 as discussed above. The second tool 222 (without the secondalignment member 416, which is located in the pinion bearing fixture 126at this point) is moved to be coaxial with the ring gear bearing fixture134. The clamping device 418 (FIGS. 10 and 11) is activated to clamp thesecond alignment member 416 to the inner sleeve 414 (FIG. 11).

Referring to FIGS. 12-14, with the second alignment member 416 clampedto the inner sleeve 414, an outward facing cylindrical surface 1310 ofthe second alignment member 416 is spaced apart from an inward facingcylindrical surface 1314 (i.e., cylindrical alignment surface) of theouter sleeve 412 to define an annular loading chamber 1318. The distancebetween the outward facing cylindrical surface 1310 and the inwardfacing cylindrical surface 1314 is slightly larger than the diameter ofeach bearing ball 84 a such that the arrangement of ring gear bearingelements 84 is received in the annular loading chamber 1318 when thesecond alignment member 416 is clamped to the inner sleeve 414. Theannular ramp surface 438 is angled to extend radially outward from theoutward facing cylindrical surface 1310 to an axial end surface 1338 todefine a gap 1322 with the inward facing cylindrical surface 1314. Thegap 1322 is smaller than the diameter of each bearing ball 84 a and eachspacer 84 b such that the ring gear bearing elements 84 are inhibitedfrom falling out of the annular loading chamber 1318. The positioningdevice 138 (FIG. 3) can then move the second tool 222 to be above andcoaxial to the ring gear 34 as shown in FIGS. 12-14.

The actuator 920 (FIG. 3) can be operated to move the race supportstructure 914 axially downward relative to the ring gear supportstructure 910, so that the first inner race member 86 is axially offsetfrom the outer bearing race 80 in the manner shown in FIG. 13. Thesecond tool 222 then moves axially downward until the outer sleeve 412contacts a surface 1326 of the ring gear 34. The inward facingcylindrical surface 1314 has a diameter that is approximately equal toor slightly less than a shoulder 1328 of the outer bearing race 80.Thus, the centers of the bearing balls 84 a are distributed along aloading cylinder 1230 (shown in FIG. 11) that has a diameter that isless than a diameter of a circle (not specifically shown) along whichthe centers of the bearing balls 84 a are distributed when seated in theouter bearing race 80 as shown in FIG. 14. The loading cylinder 1230 canhave a diameter that is equal to the corresponding staging cylinder (notspecifically shown).

The push sleeve 410 and the inner sleeve 414 can continue to moveaxially downward while the outer sleeve 412 remains stationary againstthe surface 1326 until in the position shown in FIG. 13. In thisposition, the axial end surface 1338 (i.e., race abutment surface) ofthe second alignment member 416 abuts the first inner race member 86 andthe gap 1322 has increased to be larger than the diameter of eachbearing ball 84 a and each spacer 84 b. As such, the ring gear bearingelements 84 are released and can fall under gravity into the outerbearing race 80, guided by the ramp surface 438. In the exampleprovided, the push sleeve 410 may also continue to move downwardrelative to the inner sleeve 414 and the outer sleeve 412 (e.g., to anextended position) to push the ring gear bearing elements 84 into theouter bearing race 80.

After the ring gear bearing elements 84 is seated in the outer bearingrace 80, the actuator 920 (FIG. 3) can be operated again while thesecond tool 222 retracts in order to move the first inner race member 86upwards to engage the ring gear bearing elements 84 as shown in FIG. 14.The second gripper 610 (FIG. 4) can then place the second race member 88(FIG. 2) on top of the first inner race member 86 and the fourth tool228 (FIG. 4) may optionally move the ring gear 34 with the assembledring gear bearing 78 (FIG. 2) together as a subassembly, such as intothe housing assembly 30 (FIG. 3).

Unless otherwise expressly indicated herein, all numerical valuesindicating mechanical/thermal properties, compositional percentages,dimensions and/or tolerances, or other characteristics are to beunderstood as modified by the word “about” or “approximately” indescribing the scope of the present disclosure. This modification isdesired for various reasons including industrial practice, material,manufacturing, and assembly tolerances, and testing capability.

The method steps, processes, and operations described herein are not tobe construed as necessarily requiring their performance in theparticular order discussed or illustrated, unless specificallyidentified as an order of performance. It is also to be understood thatadditional or alternative steps may be employed.

As used herein, the phrase at least one of A, B, and C should beconstrued to mean a logical (A OR B OR C), using a non-exclusive logicalOR, and should not be construed to mean “at least one of A, at least oneof B, and at least one of C.”

The description of the disclosure is merely exemplary in nature and,thus, variations that do not depart from the substance of the disclosureare intended to be within the scope of the disclosure. Such variationsare not to be regarded as a departure from the spirit and scope of thedisclosure.

What is claimed is:
 1. A method of assembling a vehicle drivelinecomponent the method comprising: providing a rotary component having acomponent body, a plurality of gear teeth and a first bearing race, thecomponent body having a rotational axis, the gear teeth and the firstbearing race being fixedly coupled to the component body; providing afirst race member of a second bearing race; positioning the rotarycomponent and the first race member of the second bearing race on afirst assembly fixture such that the first race member of the secondbearing race is located on the first assembly fixture concentric withthe first bearing race; offsetting the first race member of the secondbearing race along the rotational axis relative to the first bearingrace; providing an annular bearing arrangement having a plurality ofbearing balls and a plurality of spacers, each of the spacers beingdisposed between an associated pair of the bearing balls; positioningthe annular bearing arrangement such that the centers of the bearingballs are distributed along a loading cylinder that is disposedconcentrically about the rotational axis; and moving the annular bearingarrangement so that the plurality of bearing balls seat in the firstbearing race and the centers of the bearing balls are distributed alongan installation circle that is disposed concentrically about therotational axis, the installation circle being: a) larger in diameterthan the loading cylinder if the first bearing race is an outer bearingrace of a bearing assembly; or b) smaller in diameter than the loadingcylinder if the first bearing race is an inner bearing race of a bearingassembly.
 2. The method according to claim 1 further comprising:arranging the plurality of bearing balls and the plurality of spacersinto the annular bearing arrangement on a second assembly fixture sothat the centers of bearing balls are distributed along a stagingcylinder having a diameter that is equal to the diameter of the loadingcylinder; and removing the annular bearing arrangement from the secondassembly fixture before positioning the annular bearing arrangementconcentrically about the rotational axis.
 3. The method according toclaim 1, wherein the loading cylinder is smaller in diameter than theinstallation circle, wherein when the centers of the bearing balls ofthe annular bearing arrangement are distributed along the loadingcylinder the plurality of bearing balls includes a set of first ballsand a set of second balls, wherein the first balls are axially offsetfrom the second balls, and wherein each first ball is disposedcircumferentially between a corresponding pair of the second balls. 4.The method according to claim 1, wherein the first bearing race isunitarily and integrally formed with the component body.
 5. The methodaccording to claim 1, wherein the plurality of gear teeth are unitarilyand integrally formed with the component body.
 6. The method accordingto claim 1, wherein providing the annular bearing arrangement includesarranging the bearing balls and the spacers into the annular bearingarrangement on a second assembly fixture.
 7. The method according toclaim 6, wherein positioning the annular bearing arrangement includesmoving the annular bearing arrangement from the second assembly fixtureto the first assembly fixture.
 8. The method according to claim 1,wherein offsetting the first race member of the second bearing racealong the rotational axis includes lowering the first race member of thesecond bearing race, and wherein moving the annular bearing arrangementso that the plurality of bearing balls seat in the first bearing raceincludes releasing the annular bearing arrangement from a holder suchthat the bearing balls and spacers of the annular bearing arrangementdrop into the first bearing race.
 9. The method according to claim 1further comprising forming a subassembly that comprises the rotarycomponent, the annular bearing arrangement, and the first and secondraces, wherein the subassembly is configured such that the bearing ballsof the annular bearing arrangement are disposed between and abut thefirst bearing race and the first race member of the second bearing race.10. The method according to claim 9 further comprising installing thesubassembly as a unit to a housing, wherein the first race member of thesecond bearing race is mounted directly to the housing.
 11. A toolingsystem for assembling a subassembly to a housing, the subassemblyincluding a rotary component body, a plurality of gear teeth, a firstbearing race, a first race member of a second bearing race, and abearing arrangement, the rotary component body being rotatable about arotational axis, the plurality of gear teeth and the first bearing racebeing fixedly coupled to the rotary component body, the first racemember of the second bearing race being disposed concentrically aboutthe rotational axis, the bearing arrangement comprising a plurality ofbearing balls and a plurality of spacers, each of the spacers beingdisposed between an adjacent pair of the bearing balls, the toolingsystem comprising: a first assembly fixture including a first supportstructure and a second support structure, the first support structurebeing configured to support the rotary component body, the secondsupport structure being configured to support the first race member ofthe second bearing race concentrically about the rotational axis of therotary component body, the second support structure being movablerelative to the first support structure between a first support positionand a second support position, wherein movement of the second supportstructure between the first and second support positions translates thefirst race member of the second bearing race relative to the firstbearing race along the rotational axis; and an assembly machineincluding: a first alignment member defining a loading axis and a firstcylindrical alignment surface disposed concentrically about the loadingaxis; and a second alignment member disposed concentrically about theloading axis and having a race abutment surface that is configured toabut an axial end of the first race member, the second alignment memberbeing movable relative to the first alignment member along the loadingaxis between a first position and a second position; wherein the firstcylindrical alignment surface and the second alignment member cooperateto define an annular chamber configured to receive the bearingarrangement such that the plurality of bearing balls and the pluralityof spacers are disposed in an annular bearing arrangement that iscentered about the loading axis; and wherein when the second alignmentmember is in the second position, an end of the first cylindricalalignment surface and an end of the second alignment member are spacedapart a greater distance than when the second alignment member is in thefirst position such that when in the first position the annular bearingarrangement is retained in the annular chamber and when in the secondposition the annular bearing arrangement is free to exit the annularchamber through an annular gap between the end of the first cylindricalalignment surface and the end of the second alignment member.
 12. Thetooling system according to claim 11, wherein a diameter of the firstcylindrical alignment surface is either: a) equal to or larger than adiameter of an end of the first bearing race if the first bearing raceis an inner bearing race of a bearing assembly; or b) equal to orsmaller than a diameter of an end of the first bearing race if the firstbearing race is an outer bearing race of a bearing assembly.
 13. Thetooling system according to claim 11, wherein the second alignmentmember is disposed about the first cylindrical alignment surface and thesecond alignment member includes a ramp that tapers radially inwardtoward the end of the second alignment member.
 14. The tooling systemaccording to claim 13, wherein the assembly machine further includes apush sleeve disposed concentrically between the first cylindricalalignment surface and the second alignment member, the push sleeve beingmovable along the loading axis relative to the first alignment memberand the second alignment member between a retracted position and anextended position, wherein in the extended position the push sleeve isdisposed further into the annular chamber than when in the retractedposition.
 15. The tooling system according to claim 14 wherein theassembly machine further includes a first biasing member and a secondbiasing member, the first biasing member biasing the first alignmentmember in a first axial direction relative to the push sleeve, thesecond biasing member biasing the second alignment member in the firstaxial direction relative to the push sleeve.
 16. The tooling systemaccording to claim 11, wherein the first cylindrical alignment surfaceis disposed about the second alignment member and the second alignmentmember includes a ramp that tapers radially outward toward the end ofthe second alignment member.
 17. The tooling system according to claim16, wherein the assembly machine further includes a push sleeve disposedconcentrically between the first cylindrical alignment surface and thesecond alignment member, the push sleeve being movable along the loadingaxis relative to the first alignment member and the second alignmentmember between a retracted position and an extended position, wherein inthe extended position the push sleeve is disposed further into theannular chamber than when in the retracted position.
 18. The toolingsystem according to claim 17, wherein the assembly machine furtherincludes a first biasing member and a second biasing member, the firstbiasing member biasing the first alignment member in a first axialdirection relative to the push sleeve, the second biasing member biasingthe second alignment member in the first axial direction relative to thepush sleeve.
 19. The tooling system according to claim 11, wherein theassembly machine includes a clamp member movable between a first clampposition and a second clamp position, wherein when the clamp member isin the first clamp position the clamp member engages the secondalignment member to couple the second alignment member to the firstalignment member, and when the clamp member is in the second clampposition the clamp member is disengaged from the second alignment memberand the second alignment member is decoupled from the first alignmentmember.
 20. The tooling system according to claim 11, wherein theassembly machine includes a tool configured to pick up and move therotary component body with the annular bearing arrangement disposedbetween the first bearing race and the first race member of the secondbearing race.